Puff heat transfer

ABSTRACT

The present invention is a puff heat transfer, a puff transfer composition, and a method of making a puff transfer composition. The puff transfer composition, i.e., ink, is actually loaded with the color. In particular, the transfer composition comprises effective amounts of a transfer base material, at least one pigment concentrate, and a puff base material. The transfer base material and the pigment concentrate may be mixed together and then loaded into the puff base material to form the transfer composition. The transfer composition may be deposited on a transfer sheet to make the heat transfer. The transfer sheet may be a substrate that is treated with quillon. By using a substrate sheet that is treated with quillon, the puff of the present invention has an improved, velvet-like feel when the transfer sheet is removed.

[0001] This is a continuation-in-part of U.S. application Ser. No.09/784,531, filed Feb. 15, 2001, which is a continuation-in-part of U.S.application Ser. No. 09/413,519, filed Oct. 6, 1999, now U.S. Pat. No.6,232,041, which claimed the benefit of U.S. Provisional Application No.60/103,274, filed Oct. 6, 1998. The entirety of U.S. Pat. No. 6,232,041,U.S. application Ser. No. 09/784,531, and U.S. application Ser. No.09/413,519 are hereby incorporated by reference.

BACKGROUND AND SUMMARY OF THE INVENTION

[0002] The present invention relates generally to methods andapparatuses for reproducing art on heat transfers that are applied toclothing and other items. More particularly, the present inventionrelates to heat transfers and transfer compositions for creatingimproved puff images.

[0003] Conventional transfer technologies typically use one of threeprocesses to create a transfer image for a heat transfer. The firstprocess is the spot color or block color process, in which each actualcolor in the artwork is printed. This process generally is notcost-effective due to the number of ink colors required and has a numberof disadvantages. Resolution is low, only a limited number of colors areavailable, and there is a limited ability to achieve gradations incolor. Also, half-tones cannot be used, but rather only solid blocks ofcolor. Consequently, this process is generally suitable only for simpledesigns.

[0004] The second process is the clear carrier or Trans-Art process. Theclear carrier process uses a clear carrier layer and translucent inks.The inks used with the clear carrier process are the four-color or CMYKink pallets. Colored inks are applied to the carrier layer in thefollowing order: 1. red, 2. black, 3. blue, and 4. yellow. A whitehighlight layer is then applied.

[0005] The third conventional process creates opaque transfers usinghalf-tones. However, the resulting opaque transfers have low resolution,low color values, and poor color reproduction.

[0006] Additionally, recent direct printing technologies include use ofunlimited color pallets. Software is available for use by directprinters that allows printing of high-resolution, full-color,photographic images. The software scans in an image, selects ink colorsfrom a library, and prepares color separations that show which portionsof a screen will have a particular color applied to them and which willnot.

[0007] Direct printers generally apply a solid white base layer first,then up to eight translucent colors, generally in the following order:red, blue, purple, gold, green, turquoise, gray, brown, white(highlight), and black. Commercial software is available to assistdirect printers in obtaining color separations and color densities fromscanned-in artwork.

[0008] Direct printing technology is not suitable for printingtransfers. Transfers are printed in reverse color order so that thecorrect image appears on the substrate to which the transfer is applied.Transfers also must be printed so the desired arrangement of colorsappears at the ink split rather than the upper surface of the transfersheet.

[0009] In addition to the above shortcomings, conventional puff heattransfers have further drawbacks. In a conventional puff heat transfer,color is not loaded into the puff material. Instead, a plastisol inkcolor is first applied to the transfer sheet. Thereafter, a clear orneutral puff material is applied on top of the plastisol ink color.Consequently, the color is influenced by the clear or neutral puffmaterial when the image is transferred to a piece of clothing or anyother item. This can result in a dull and unappealing image.

[0010] Conventional puff heat transfers also fail to provide a desiredfeel. These puff heat transfers commonly use paper that is notadequately treated as the transfer sheet. Consequently, when thetransfer sheet is removed, it also tears away some of the puff material.This leads to a puff image that feels somewhat rough.

[0011] In light of the above shortcomings, one aspect of the presentinvention contemplates a new and improved method for making heattransfers with opaque inks which is simple in design, effective in use,and overcomes at least some of the foregoing difficulties and otherswhile providing better and more advantageous overall results.Furthermore, the present invention provides puff transfer compositionshaving improved characteristics including, but not limited to, washingcharacteristics and printing characteristics.

[0012] In accordance with one embodiment of the present invention, a newand improved method for reproducing fine art on heat transfers that areapplied to clothing and other items is provided which creates highquality transfers.

[0013] According to one aspect of the present invention, a method ofmaking a heat transfer from an image for application to a T-shirt orother piece of cloth is disclosed. The method includes the steps ofscanning the image to create a computer image represented by a computerreadable image file; separating the computer image into a plurality ofcolors using a computer to create a separated image; creating aplurality of plates from the separated image; each of the plurality ofplates corresponding to one of the plurality of colors; printing each ofthe plurality of plates on film to create a plurality of colorseparation films; the color separation films having printed mattercorresponding to one of the plurality of colors; treating a plurality ofmesh screens with a photoemulsion; placing the plurality of colorseparation films on the plurality of mesh screens; applying light to themesh screens, a portion of the photoemulsion hardening in the light anda second portion of the photoemulsion covered by the printed matter onthe color separation films remaining soft; washing the plurality of meshscreens to remove the second portion of the photoemulsion; and applyingink to a piece of transfer paper through the plurality of mesh screens.

[0014] One advantage of the present invention is that bright, opaquetransfers are created that may be applied to dark color shirts. Anotheradvantage of the present invention is that the images created on theheat transfers look nearly identical to the original artwork. Yetanother advantage of the present invention is that a wide range ofcolors may be achieved using a reasonable (cost-effective) number of inkcolor layers.

[0015] Another embodiment of the present invention is a transfercomposition that loads the color into the puff material. In thisembodiment, the transfer composition comprises a puff base material andat least one pigment concentrate. The puff base material is included inan amount of at least about 85% by weight. On the other hand, thepigment concentrate is in a total amount of about 15% by weight or less.Consequently, this feature of the present improves the color quality ofimages that can be applied by puff heat transfers.

[0016] Another embodiment of the puff transfer composition of thepresent invention is also loaded with the color. This exemplary transfercomposition comprises a transfer base material, at least one pigmentconcentrate, and a puff base material. The transfer base material may beincluded in amount of at least about 25% by weight, and the puff basematerial may be included in an amount of at least about 35% by weight.On the other hand, the pigment concentrate may be in a total amount ofabout 40% by weight or less. The transfer base material and the pigmentconcentrate may be mixed together and then loaded into the puff basematerial to form the transfer composition. Exemplary embodiments of thistransfer composition offer significantly improved printing and washingcharacteristics while still being effective for making high colorquality puff transfers.

[0017] The present invention includes still another embodiment of thepuff transfer composition that is loaded with the color. This exemplarytransfer composition also comprises a transfer base material, at leastone pigment concentrate, and a puff base material. The transfer basematerial may be included in amount of at least about 25% by weight, andthe puff base material may be included in an amount of at least about65% by weight. On the other hand, the pigment concentrate may be in atotal amount of about 10% by weight or less. The transfer base materialand the pigment concentrate may be mixed together and then loaded intothe puff base material to form the transfer composition. Exemplaryembodiments of this transfer composition offer significantly improvedprinting and washing characteristics while still being effective formaking high color quality puff transfers.

[0018] The present invention is not limited to the exemplary embodimentsof the puff transfer composition that are noted above. The presentinvention includes all other variations of the puff transfer compositionthat include effective amounts of transfer base material, at least onepigment concentrate, and puff base material. As used herein, a pufftransfer composition includes effective amounts of the ingredients if itis suitable for making heat transfers.

[0019] The present invention also includes a puff transfer. In thisaspect of the present invention, the transfer comprises an ink image ona substrate sheet. The sheet of substrate is treated with quillon, andthe ink image is made of a transfer composition, e.g., a puff transfercomposition of the present invention or any other similar, suitable, orconventional puff or non-puff composition. By using a substrate sheetthat is treated with quillon, the inventors have surprisingly discoveredthat a puff transfer has an improved, velvet-like feel when the transfersheet is removed. This beneficial effect is due to the improved releaseof the pigment concentrate by the quillon-treated paper.

[0020] The present invention also includes a method of making a puffimage on an article. The method comprises the steps of making a transfercomposition, e.g., a puff transfer composition of the present inventionor any other similar, suitable, or conventional puff transfercomposition. The transfer composition is deposited on a substrate toform a transfer which is then positioned on an article. Heat andpressure are applied to the substrate to transfer the transfercomposition onto the article, and the transfer composition is adapted topuff. This embodiment of the present invention can further include anyof the optional or preferred embodiments of the present invention.

[0021] In addition to the novel features and advantages mentioned above,other objects and advantages of the present invention will be readilyapparent from the following descriptions of the drawings and exemplaryembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The invention may take physical form in certain parts andarrangement of parts, a preferred embodiment of which will be describedin detail in this specification and illustrated in the accompanyingdrawings that form a part of this document.

[0023]FIG. 1 shows a perspective view of a heat transfer;

[0024]FIG. 2 shows a color separation plate;

[0025]FIG. 3 shows a view of an overlay of several color separationplates;

[0026]FIG. 4 shows a close-up view of a color separation printed onfilm;

[0027]FIG. 5 shows a perspective view of a mesh screen with a colorseparation film;

[0028] FIGS. 6 shows an image; and

[0029] FIGS. 7-15 show color separations according to the presentinvention of the image of FIG. 6.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

[0030] The present invention is directed to heat transfers and transfercompositions. The present invention also includes methods of making andapplying heat transfers. The heat transfers of the present invention canbe applied to any desired items. For instance, the heat transfers can beused with articles that are known to receive transfers including, butnot limited to, fabric items such as clothing, luggage, bags, backpacks,and other similar, suitable, or conventional materials.

[0031] The transfers are made in two general steps, a pre-press step inwhich screens are prepared for printing the transfers and a printingstep in which ink is applied to transfer paper through the screens.Referring now to the drawings which show an example of one embodiment ofthe invention, FIGS. 1 through 5 concern the application of opaque inksfor reproducing art on a heat transfer 10. A heat transfer 10 includesan image 14 created with ink 18 and applied to heat transfer sheet 22.When a heat source is applied to a heat transfer 10, the ink 18 istransferred from the heat transfer sheet 22 to a piece of fabric (notshown) on which the heat transfer 10 is placed, such as a T-shirt.

[0032] The first step of the process for producing the improved heattransfer 10 is the selection of the image 14. After the image isselected, the image 14 may be scanned into a computer. In the preferredembodiment, the image 14 is scanned as a RGB tiff file, which differsfrom other printing methods. The scanned image is then preferably colorcorrected and digitally altered, or “cleaned up,” to match the originalimage 14. Throughout the entire process, the image 14 is maintained inthe RGB format. When the altered, scanned image is closely matched tothe original image, the next step of the process may include theseparation of colors.

[0033] A color separation may be prepared to separate the image colorsinto component ink colors. This is particularly useful when a compleximage is desired that is comprised of many different variations ofcolors. The color separation process can be used to separate the imagecolors into component ink colors that, when combined, will yield a heattransfer image as close as possible to the altered scanned image. Theink colors are preferably selected so the best and brightest colors arethe exact colors that are printed based on the selection of inks, andnot the colors that require a combination of inks, thereby producing thebest overall results. Superior results are obtained with images thatcontain the colors white, blue, red, gold, purple, green, turquoise,gray, black, and brown. FIG. 2 shows a color separation 26. Colorseparations 26 may be half-tone printouts (made up of dots, like anewspaper photo) on a transparent film 34. The image 14 is separatedinto colors by selecting the area of the image 14 in which the colorexists or the color is used to make another color. The printouts havedots in regions where a particular color is to be applied to thetransfer 10. A different half-tone film is made for each ink color to beapplied to the transfer. The computer assigns a particular ink colorwithin a given color family from an ink library based on the colorpallet and color densities using a standard direct printing software,such as a program called “Spot Process,” which is produced by FreehandGraphics. As written, the software does not achieve a satisfactoryresult because of differences between direct printing and transfermanufacturing. Transfer inks must be applied in a different order thandirect printing inks. In some instances, the transfer ink layers mayalso be thicker than direct print ink layers because the ink layer maybe “split” when the transfer is applied. When the transfer is heated, aportion of the inks may adhere to the surface and a portion may remainon the transfer sheet depending on the release qualities of the transfersheet. The ink “split” also affects color blending and shading.Knowledge about where in the ink layer this split will occur, which is acharacteristic of the chosen inks, assists in obtaining finer gradationsof color shading. Therefore, the standard software has been modified toalter the number and sequence of process steps to achieve satisfactorytransfers. Specifically, the colors have been modified from beingtranslucent to preferably up to 100% opaque and a white base is used toallow application of the transfer to a substrate of any color and toachieve desired resolution. Also, the print rotation has been reversedto reflect the fact that a transfer is a negative image rather than apositive image.

[0034]FIG. 6 shows an image 14. FIGS. 7 through 15 show colorseparations 26 of the image 14. In particular, FIG. 7 is black ink, FIG.8 is white ink, FIG. 9 is brown ink, FIG. 10 is gray ink, FIG. 11 ispurple ink, FIG. 12 is gold ink, FIG. 13 is blue ink, FIG. 14 is redink, and FIG. 15 is white base.

[0035] First, a “white base” may be selected. This is the plate 30 thatis printed to go behind all of the other colors to help make the designopaque and to help make lighter shades of other colors. The area isselected, and a plate or channel is printed of the selection. The resultis a gray scaled plate of the selection that looks similar to a blackand white photograph, as shown in FIG. 2.

[0036] For the second step, red may be selected. The area of the imagethat contains red or that needs red to create another color, such aspink, is selected. A plate 30 or channel is then created for theselection. The process continues for the remaining colors according tothe printing order. As the plates are overlaid, as shown in FIG. 3, theillusion of more and different colors is created.

[0037] The order the colors are printed is opposite of what a vieweractually sees because a transfer 10 is a negative image. For thepre-press work, the order of printing is white base, red, blue, gold,purple, green, turquoise, gray, white, black, and brown. The first whitebase is for opacity and shading. The second white is for bright white inthe image 14. Brown is only used when needed, such as in the creation offlesh tones or when brown is part of the image. After all of the plates30 are made, the image 14 is viewed with the plates 30 together so thatthey cover completely and produce a multi-colored, opaque image 14. Whenthe image is satisfactory, the plates are separated and printed on film34. All printing is made of dots 38 which lay on top of each other ornext to each other with half-tone inks. The printing of dots 38 for thismethod lay next to each other and are printed 45 lines per inch. Aclose-up view of a separation 26 printed on film 34 is shown in FIG. 4.

[0038] The color separation films 34 with half-tones are placed on amesh screen 42 to which a light-sensitive photoemulsion has beenapplied. The mesh 42 may be made of polyester, nylon, or a combinationof these, with openings of a desired size. An example of the mesh screen42 is Saati 40 T mesh which is commercially available from Saati. Thisexample of the mesh is a monofilament polyester. On the other hand, anexample of the photoemulsion is Marathon Z which is commerciallyavailable from Majestech. Marathon Z is a dual cure photopolymer havinga 40% solids content. Generally, the finer the mesh 42, the finer theresolution and shading possible. Conversely, a coarser mesh 42 may beused for images that require a lower degree of resolution. When making apuff transfer, a relatively coarse mesh 42 may be used to improve thepuff characteristics, e.g., the millage (i.e., thickness) of the puff.The screen 42 is exposed to light, such as ultraviolet (UV) light,causing the photoemulsion to harden in the areas without half-tones. Theemulsion remains soft in the areas under the half-tones because thelight did not penetrate through the half-tones. The soft emulsion isremoved by rinsing, thereby leaving open mesh areas through which ink 18will be applied to the transfer sheet 22. The hardened emulsion forms aseal over the mesh perforations in other areas. A different screen 42 isprepared for each color to be applied. Stretching of the mesh 42 so thatit exposes properly is important in obtaining good resolution.

[0039] The inks 18 are applied in a different order than a directprinter would apply ink. In an exemplary embodiment, the order ofapplication is: black, white highlight, brown, gray, turquoise, green,gold, purple, blue, red, and white. A direct printer generally requiresadditional ink layers (one black and one white) compared to a transfermanufacturer. It is possible to make a transfer 10 without using all ofthese colors for relatively simple art, but use of all of these colorsmay be necessary to make a realistic, photographic quality multi-colortransfer image.

[0040] Conventional machinery is used to apply ink 18 to the transferpage through the screens 42 in a predetermined order. For areas of theimage that require a combination of colors, this process builds up thedesired number of ink layers in the desired area. Registration(consistent alignment of the screens relative to the transfer paper onall runs) also is important in obtaining good resolution. Due to thenature of puff transfers, it is preferred to use only a single layer ofink 18 to achieve the desired colors of the image. However, it should berecognized that a puff transfer may also employ stacked ink layers toachieve a desired result.

[0041] The transfer sheet 22 used in making the transfer 10 must providestable retention of ink 18 on the sheet 22 until the transfer 10 isapplied and facilitate release of the ink 18 during application. If thesheet 22 releases ink 18 too easily, the ink 18 can practically be movedon the transfer 10 by blowing on it, which would result in an image 14that is blurry. On the other hand, if the sheet 22 does not release ink18 easily enough, it will be difficult to cleanly transfer the image 14from the sheet 22 to an article. An example of the sheet 22 is a totalrelease paper that is treated with photopolymer silicone. In thisembodiment, the sheet 22 may allow the ink 18 to split withapproximately 90-95% of the ink 18 being released from the sheet 22 whenheated in the traditional method. The increased release of ink 18 fromthe sheet 22 over a non-treated paper, which releases about 50% of theink, helps the released ink 18 to maintain a high level of opacity. Theamount of ink 18 released from the sheet 22 may vary depending on howeven the ink 18 was originally applied and the evenness of the siliconecoating on the sheet 22.

[0042] Another example of the sheet 22 is a substrate that is treatedwith quillon or a similar chemical. An example of a quillon-treatedsubstrate is Burkhardt/Freeman 31×45 ultra strip smooth treated C2S 65pounds, lot number 39614, or any other similarly treated sheet. Thesubstrate may be paper or any other substrate that is suitable for beingtreated or otherwise coated by the quillon or a similar chemical. Theinventors have made the surprising discovery that using aquillon-treated substrate results in even more improved release of theink upon application. In particular, the quillon-treated substrate canrelease up to substantially 100% of the ink from the substrate whenheated in a conventional application process. The improved release cangive the image, especially a puff transfer image, a velvet-like feel.

[0043] The ink 18 may be any brand of plastisol ink in non-puffembodiments of the present invention. Plastisol inks typically comprisea resin, polyvinyl chloride, and a coloring agent. Consistent inkproperties are important in achieving acceptable results. The ink 18preferably has a shear rate sufficient to provide the necessary opacityand acceptable ink split. The ink 18 also preferably has a viscositythat allows printing the desired number of lines per inch.

[0044] On the other hand, the ink 18 has different ingredients for puffheat transfers. In one embodiment, the ink 18 for puff heat transfers iscomprised of a puff base material and at least one pigment concentrate.The puff base material and the pigment concentrate may be mixed togetherby any conventional or suitable method. The puff base materialpreferably comprises at least about 85%, more preferably at least about90%, still more preferably at least about 92%, by weight of the ink 18.On the other hand, the total amount by weight of pigment concentrate ispreferably about or less than 15%, more preferably about or less than10%, and even more preferably about or less than 8%. However, it shouldbe recognized that in optional embodiments of the present invention thepuff base may account for less than about 85% by weight of thecomposition and the pigment concentrate may account for more than 15% byweight of the composition.

[0045] In another embodiment, the ink 18 for puff transfers is comprisedof effective amounts of a transfer base material, at least one pigmentconcentrate, and a puff base material. The transfer base material, thepigment concentrate, and the puff base material may be mixed together inany order by any conventional or suitable method. Nevertheless, it hasbeen discovered that the resultant transfer composition exhibitsimproved washing and printing characteristics when the transfer basematerial and the pigment concentrate are first mixed together and thenloaded into the puff base material.

[0046] In one embodiment, the transfer base material may comprise atleast about 25%, more preferably at least about 30%, still morepreferably at least about 32%, even more preferably at least about 34%,by weight of the ink 18. On the other hand, the total amount by weightof pigment concentrate in this embodiment of the transfer compositionmay be about or less than 40%, more preferably about or less than 30%,still more preferably about or less than 25%, and even more preferablyabout or less than 20%. The puff base material may account for at leastabout 35%, more preferably at least about 40%, still more preferably atleast about 43%, even more preferably at least about 46%, by weight ofthe ink 18 in this embodiment. Nevertheless, it should be recognizedthat some embodiments of the ink 18 of the present invention maycomprise about 0% to about 25% by weight of the transfer base material,about 40% to about 100% by weight of the pigment concentrate, and/orabout 0% to about 35% by weight of the puff base material. Four furtherexemplary embodiments of this puff transfer composition are providedbelow: % By Weight Transfer Base Material 25-52 Pigment Concentrate0.1-40  Puff Base Material 35-68 Transfer Base Material 30-47 PigmentConcentrate 0.1-30  Puff Base Material 40-63 Transfer Base Material32-45 Pigment Concentrate 0.1-25  Puff Base Material 43-60 Transfer BaseMaterial 34-43 Pigment Concentrate 0.1-20  Puff Base Material 46-57

[0047] In another embodiment of the puff transfer composition, thetransfer base material may be included in amount of at least about 25%by weight, and the puff base material may be included in an amount of atleast about 65% by weight. On the other hand, the pigment concentratemay be in a total amount of about 10% by weight or less. Again, itshould be recognized that some embodiments of the ink 18 of the presentinvention may comprise about 0% to about 25% by weight of the transferbase material, about 10% to about 100% by weight of the pigmentconcentrate, and/or about 0% to about 65% by weight of the puff basematerial. Each of the exemplary puff transfer compositions may be madeusing the same or similar manufacturing equipment and conditions.

[0048] The puff base material is adapted to provide puffcharacteristics, and it is suitable for use with puff transferapplications. Accordingly, the puff base material may be any puff basethat is conventional, suitable, or commercially available now or in thefuture. Examples of the puff base material include, but are not limitedto, the TF 10480 neutral base and the XDG49234BD neutral base which areavailable from Wilflex Inc. and other similar, suitable, or conventionalpuff base materials. It is believed that the puff base TF 10480 iscomprised of resin, base, adhesive, and blowing agent. It is believedthat the XDG49234BD neutral base is also comprised of resin, base,adhesive, and blowing agent.

[0049] The pigment concentrate may be any suitable, conventional, orcommercially available pigment concentrate. Examples of the pigmentconcentrate include, but are not limited to, pigment concentrates thatare commercially available from Wilflex Inc. and other similar,suitable, or conventional pigment concentrates. In the presentinvention, pigment concentrate is preferably used in the puff transfercomposition instead of plastisol ink. As noted above, plastisol inkcontains other ingredients in addition to the pigment concentrate. Theadditional ingredients in the plastisol ink can be detrimental to thequality of the puff. Most importantly, the additional ingredients canhold down the puff and cause the puff to collapse. For similar reasons,it may be desired to limit the amount of pigment concentrate in the pufftransfer compositions as noted above.

[0050] The transfer base material may be any suitable, conventional, orcommercially available base material that is adapted for use withtransfer applications. An example of the transfer base materialincludes, but is not limited to, the TF 10440 neutral base which isavailable from Wilflex Inc. and other similar, suitable, or conventionaltransfer base materials. It is believed that the transfer base TF 10440is comprised of resin and plasticizer.

[0051] Various manufacturing considerations can affect the quality ofthe puff. The inventors have discovered that the size of the mesh caninfluence the millage, i.e., thickness of the puff. The puff preferablyhas a millage of at least about 2.5 mils, more preferably at least about3.0 mils, still more preferably at least about 4.0 mils, and even morepreferably at least about 5.0 mils. It is preferred to use mesh size 40T or coarser to obtain optimal millage. Accordingly, a puff transfer ofthe present invention is particularly well-suited for images that do notrequire a high degree of resolution. However, optional embodiments ofthe present invention may use finer mesh, e.g., mesh size up to andpossibly exceeding 70 T.

[0052] The drying temperature and time of the puff transfer can alsodetermine the quality of the puff. After an ink is applied to thetransfer sheet, the transfer sheet is preferably passed through a dryerto gel the ink. A belt may be used to pass the transfer sheet throughthe dryer. A conventional dryer may be used. An example of the dryer isa gas-fired dryer that is commercially available from S.P.E. inCalifornia. The drying temperature and time can be adjusted to suit aparticular dryer temperature and belt speed. It is preferred to maintainthe dryer temperature between about 225 and 320 degrees Fahrenheit (morepreferably between about 250 and 280 degrees Fahrenheit) and theresidence time in the dryer to between about 10 and 35 seconds. However,it should be noted that the dryer temperature and residence time mayvaried outside of these ranges to obtain any desired characteristics ofthe puff.

[0053] The completed transfer may be heat applied to clothing or otheritems using conventional transfer presses. Examples of a transfer pressinclude, but are not limited to, a commercially available SakauriCylinder press, a hand bench press, or any other similar, suitable, orconventional transfer press. Satisfactory results may be obtained usinga press temperature of about 375-395° F., a platen pressure of about45-60 psi, and a dwell time of about 4-15 seconds.

EXAMPLE

[0054] An image was made using TF 19000 Black, Pantone Orange 021 C,Pantone Violet C, Pantone 339 C, Pantone 300 C, Pantone 185 C, andPantone Yellow C. The TF 19000 Black was applied to the transfer sheetusing a 160 T mesh screen, and the other inks were each applied using arespective 40 T mesh screen. In particular, the following puff transfercompositions were used in addition to the TF 19000 Black to make theimage: Pantone Orange 021 C TF 10480 Puff Base 4000 grams PCM Yellow 225 grams PCM Red  25 grams Pantone Violet C TF 10480 Puff Base 4000grams PCM Violet  100 grams PCM Fluorescent Purple  50 grams Pantone 339C TF 10480 Puff Base 4000 grams PCM Green  250 grams PCM Blue  25 gramsPCM Fluorescent Yellow  10 grams Pantone 300 C TF 10480 Puff Base 4000grams PCM Blue  100 grams PCM Fluorescent Blue  80 grams Pantone 185 CTF 10480 Puff Base 4000 grams PCM Red  150 grams PCM Yellow  35 gramsPCM Fluorescent Pink  25 grams Pantone Yellow C TF 10480 Puff Base 4000grams PCM Yellow  175 grams

EXAMPLE

[0055] An image was made using TF 19000 Black, Pantone Orange 021 C,Pantone 224 C, Pantone 264 C, Pantone 360 C, Pantone 324 C, Pantone 381C, and Pantone 136 C. The TF 19000 Black was applied to the transfersheet using a 160 T mesh screen, and the other inks were each appliedusing a respective 40 T mesh screen. In particular, the following pufftransfer compositions were used in addition to the TF 19000 Black tomake the image: Pantone Orange 021 C TF 10480 Puff Base 4000 grams PCMYellow  225 grams PCM Red  25 grams Pantone 224 C TF 10480 Puff Base4000 grams PCM White  60 grams PCM Magenta  30 grams PCM FluorescentPink  50 grams Pantone 264 C TF 10480 Puff Base 4000 grams PCM White 140 grams PCM Violet  15.7 grams PCM Fluorescent Pink   2.5 gramsPantone 360 C TF 10480 Puff Base 4000 grams PCM White  100 grams PCMYellow  180 grams PCM Green  35 grams PCM Blue   1 gram Pantone 324 C TF10480 Puff Base 4000 grams PCM White  145 grams PCM Green   9 grams PCMBlack   1 gram PCM Fluorescent Yellow   2 grams Pantone 381 C TF 10480Puff Base 4000 grams PCM White  96 grams PCM Yellow  170 grams PCM Green 20 grams PCM Fluorescent Yellow  10 grams Pantone 136 C TF 10480 PuffBase 4000 grams PCM White  106 grams PCM Yellow  125 grams PCM Red   5grams PCM Marine   1 gram

EXAMPLE

[0056] An image was made using TF 19000 Black, Pantone 1355 C, Pantone264 C, Pantone 3242 C, Pantone 2905 C, Pantone 182 C, and Pantone 100 C.The TF 19000 Black was applied to the transfer sheet using a 160 T meshscreen, and the other inks were each applied using a respective 40 Tmesh screen. In particular, the following puff transfer compositionswere used in addition to the TF 19000 Black to make the image: Pantone1355 C TF 10480 Puff Base 4000 grams PCM White  140 grams PCM Yellow  56grams PCM Magenta   8.9 grams PCM Marine   1.5 grams Pantone 264 C TF10480 Puff Base 4000 grams PCM White  140 grams PCM Violet  29.5 gramsPCM Fluorescent Pink   4 grams Pantone 3242 C TF 10480 Puff Base 4000grams PCM White  170 grams PCM Green  20 grams PCM Blue   1.5 grams PCMFluorescent Yellow   3.5 grams Pantone 2905 C TF 10480 Puff Base 4000grams PCM White  140 grams PCM Marine  45 grams PCM Blue   4 grams PCMFluorescent Yellow   5.5 grams Pantone 182 C TF 10480 Puff Base 4000grams PCM White  140 grams PCM Fluorescent Yellow  25 grams PCM Red 11.5 grams PCM Fluorescent Blue   1 gram Pantone 100 C TF 10480 PuffBase 4000 grams PCM White  140 grams PCM Yellow  30 grams

EXAMPLE

[0057] Puff transfers were made according to the present invention usinga 40 T mesh. The image was comprised of the following colors: PantoneViolet C, Pantone Process Blue C, Pantone Green C, Pantone Red 032 C,Pantone Yellow C, and Pantone Orange 021 C. All of the inks were mixedwith no more than 15% by weight pigment concentrate loads. Each transfersheet was Burkhardt/Freeman 31×45 ultra strip smooth treated C2S 65pounds, lot number 39614. After the application of each ink, therespective transfer sheet was passed through a 280 degree Fahrenheitgas-fired dryer for about 26 seconds on a belt travelling at a speed ofabout 46 feet per minute. Drying and stacking of the transfers wassuccessful. One of the completed transfers was then applied to a pieceof clothing using a Sakauri Cylinder Press. The transferred image had amillage of about 5.0 to 5.25 while still wet.

EXAMPLE

[0058] A second transfer was manufactured under the same conditions asdescribed in the above example. However, in this example, a transfer wasapplied with a hand bench press to an article of clothing. While stillwet, the transferred image had a millage of about 3 to about 3.25.

EXAMPLE

[0059] In this example, a 40 T mesh was used in the application of theinks to the transfer sheet. The dryer temperature was about 280 degreesFahrenheit, and the belt speed was increased to 65 feet per minute.Accordingly, the residence time in the dryer was decreased to about 18.5seconds. The image was transferred to an article of clothing using aSakauri Cylinder Press. This resulted in a puff image having a thicknessof about 5.25 mils.

EXAMPLE

[0060] An image was made using Pantone 021 C, Pantone 224 C, Pantone 264C, Pantone 360 C, Pantone 3105 C, Pantone 381 C, and Pantone 136 C. Incontrast to the previous examples, each of the pigment concentrates werefirst mixed together with the transfer ink base material. Thereafter,the puff base material was added to the mix. The transfer was made usingthe same or similar manufacturing conditions and techniques as describedabove. The resultant transfer exhibited puff characteristics that werethe same or similar as those described above. Moreover, the inventorssurprisingly discovered that the combination of the transfer basematerial (TF 10440) and the puff base material (XDG49234BD) resulted ina transfer composition that exhibited improved printing and washingcharacteristics. The transfer was easier to print, and the transfermaintained its integrity better in the wash. Pantone 021 C TF 10440 Base1500 grams PCM Red  25 grams PCM Yellow  70 grams XDG49234BD Puff Base2000 grams Pantone 224 C TF 10440 Base 1500 grams PCM White  40 gramsPCM Magenta  15 grams PCM Fluorescent Pink  20 grams XDG49234BD PuffBase 2000 grams Pantone 264 C TF 10440 Base 1500 grams PCM White  80grams PCM Violet  12 grams PCM Fluorescent Pink   3 grams XDG49234BDPuff Base 2000 grams Pantone 360 C TF 10440 Base 1500 grams PCM White 60 grams PCM Blue   1 gram PCM Green  20 grams PCM Yellow  120 gramsXDG49234BD Puff Base 2000 grams Pantone 3105 C TF 10440 Base 1500 gramsPCM White  70 grams PCM Blue   6 grams PCM Green   8 grams XDG49234BDPuff Base 2000 grams Pantone 381 C TF 10440 Base 1500 grams PCM White 66 grams PCM Green  12 grams PCM Yellow  110 grams PCM FluorescentChartreuse  15 grams XDG49234BD Puff Base 2000 grams Pantone 136 C TF10440 Base 1500 grams PCM White  65 grams PCM Red   5 grams PCM Marine  0.25 gram PCM Yellow  80 grams XDG49234BD Puff Base 2000 grams

EXAMPLE

[0061] An image was made using Pantone 021 C, Pantone Violet C, Pantone339 C, Pantone 300 C, Pantone 185 C, and Pantone Yellow C. Each of thepigment concentrates was first mixed together with the transfer ink basematerial. Thereafter, the puff base material was added to the mix. Thetransfer was made using the same or similar manufacturing conditions andtechniques as described above. The resultant transfer exhibited puffcharacteristics that were the same or similar as those described above.Moreover, the combination of the transfer base material (TF 10440) andthe puff base material (XDG49234BD) resulted in a transfer compositionthat again exhibited improved printing and washing characteristics. Thetransfer was easier to print, and the transfer maintained its integritybetter in the wash. Pantone 021 C TF 10440 Base 1500 grams PCM Red  25grams PCM Yellow  70 grams XDG49234BD Puff Base 2000 grams PantoneViolet C TF 10440 Base 1500 grams PCM Violet  66 grams PCM FluorescentPurple  30 grams XDG49234BD Puff Base 2000 grams Pantone 339 C TF 10440Base 1500 grams PCM Blue  16 grams PCM Green  160 grams PCM FluorescentChartreuse  10 grams XDG49234BD Puff Base 2000 grams Pantone 300 C TF10440 Base 1500 grams PCM Blue  70 grams PCM Fluorescent Blue  50 gramsXDG49234BD Puff Base 2000 grams Pantone 185 C TF 10440 Base 1500 gramsPCM Red  150 grams PCM Yellow  16 grams PCM Fluorescent Pink  16 gramsXDG49234BD Puff Base 2000 grams Pantone Yellow C TF 10440 Base 1500grams PCM Yellow  110 grams XDG49234BD Puff Base 2000 grams

EXAMPLE

[0062] An image was made using Pantone 193 C, Pantone 258 C, Pantone 363C, Pantone 457 C, Pantone 465 C, and Pantone 542 C. Each of the pigmentconcentrates was first mixed together with the transfer ink basematerial. Thereafter, the puff base material was added to the mix. Thetransfer was made using the same or similar manufacturing conditions andtechniques as described above. This resultant transfer also exhibitedpuff characteristics that were the same or similar as those describedabove. Again, the combination of the transfer base material (TF 10440)and the puff base material (XDG49234BD) resulted in a transfercomposition that exhibited improved printing and washingcharacteristics. The transfer was easier to print, and the transfermaintained its integrity better in the wash. Pantone 193 C TF 10440 Base1500 grams PCM White  30 grams PCM Magenta  100 grams PCM Red  200 gramsPCM Black   1 gram XDG49234BD Puff Base 2000 grams Pantone 258 C TF10440 Base 1500 grams PCM White  391 grams PCM Magenta  165 grams PCMMarine  103 grams XDG49234BD Puff Base 2000 grams Pantone 363 C TF 10440Base 1500 grams PCM White  200 grams PCM Blue  38 grams PCM Yellow  270grams PCM Black   1.5 grams XDG49234BD Puff Base 2000 grams Pantone 457C TF 10440 Base 1500 grams PCM White  20 grams PCM Red   3 grams PCMMarine  15 grams PCM Yellow  300 grams PCM Black   1 gram XDG49234BDPuff Base 2000 grams Pantone 465 C TE 10440 Base 1500 grams PCM White 550 grams PCM Magenta   4 grams PCM Violet  10 grams PCM Yellow  45grams PCM Black   1 gram XDG49234BD Puff Base 2000 grams Pantone 542 CTF 10440 Base 1500 grams PCM White  520 grams PCM Marine  280 grams PCMBlue  12 grams PCM Black   8 grams XDG49234BD Puff Base 2000 grams

EXAMPLE

[0063] An image was made using Pantone 801 C, Pantone 802 C, Pantone 803C, Pantone 804 C, Pantone 805 C, and Pantone 807 C. Each of the pigmentconcentrates was first mixed together with the transfer ink basematerial and then loaded into the puff base material. The transfer wasmade using the same or similar manufacturing conditions and techniquesas described above. The resultant transfer exhibited puffcharacteristics that were the same or similar as those described above.Moreover, the combination of the transfer base material (TF 10440) andthe puff base material (XDG49234BD) resulted in a transfer compositionthat again exhibited improved printing and washing characteristics. Thetransfer was easier to print, and the transfer maintained its integritybetter in the wash. Pantone 801 C TF 10440 Base 1500 grams PCM White  35grams PCM Blue  20 grams PCM Fluorescent Blue  300 grams XDG49234BD PuffBase 2000 grams Pantone 802 C TF 10440 Base 1500 grams PCM White  40grams PCM Green   5 grams PCM Fluorescent Chartreuse  20 grams PCMFluorescent Green  40 grams XDG49234BD Puff Base 2000 grams Pantone 803C TF 10440 Base 1500 grams PCM White  50 grams PCM Yellow  25 grams PCMFluorescent Chartreuse  225 grams PCM Fluorescent Pink   1.5 gramsXDG49234BD Puff Base 2000 grams Pantone 804 C TF 10440 Base 1500 gramsPCM White  40 grams PCM Red  30 grams PCM Yellow  400 grams PCMFluorescent Pink  90 grams XDG49234BD Puff Base 2000 grams Pantone 805 CTF 10440 Base 1500 grams PCM White  10 grams PCM Red  60 grams PCMYellow  225 grams PCM Fluorescent Pink  325 grams XDG49234BD Puff Base2000 grams Pantone 807 C TF 10440 Base 1500 grams PCM White   6 gramsPCM Violet   6 grams PCM Fluorescent Pink  450 grams XDG49234BD PuffBase 2000 grams

EXAMPLE

[0064] An image was made using a puff transfer composition comprising atleast 25% by weight of a transfer base material, at least 65% by weightof a puff base material, and about 10% or less by weight of pigmentconcentrates. Each of the pigment concentrates was first mixed togetherwith the transfer ink base material and then loaded into the puff basematerial. The transfer was made using the same or similar manufacturingconditions and techniques as described above. The resultant transferexhibited puff characteristics that were the same or similar as thosedescribed above. Moreover, the combination of the transfer base material(TF 10440) and the puff base material (XDG49234BD) resulted in atransfer composition that again exhibited improved printing and washingcharacteristics. The transfer was easier to print, and the transfermaintained its integrity better in the wash.

[0065] The exemplary embodiments herein disclosed are not intended to beexhaustive or to unnecessarily limit the scope of the invention. Theexemplary embodiments were chosen and described in order to explain theprinciples of the present invention so that others skilled in the artmay practice the invention. Having shown and described exemplaryembodiments of the present invention, those skilled in the art willrealize that many variations and modifications may be made to affect thedescribed invention. Many of those variations and modifications willprovide the same result and fall within the spirit of the claimedinvention. It is the intention, therefore, to limit the invention onlyas indicated by the scope of the claims.

What is claimed is:
 1. A transfer composition comprising: a transferbase material in an effective amount; a puff base material in aneffective amount; and at least one pigment concentrate in an effectiveamount.
 2. The transfer composition of claim 1 wherein: said transferbase material is in an amount of at least about 25% by weight; said puffbase material is in an amount of at least about 65% by weight; and saidpigment concentrate is in a total amount of about 10% by weight or less.3. The transfer composition of claim 1 wherein: said transfer basematerial is in an amount of at least about 25% by weight; said puff basematerial is in an amount of at least about 35% by weight; and saidpigment concentrate is in a total amount of about 40% by weight or less.4. The transfer composition of claim 1 wherein said puff base materialis comprised of a resin, a base, an adhesive, and a blowing agent. 5.The transfer composition of claim 1 wherein said transfer base materialis comprised of a resin and a plasticizer.
 6. A transfer comprising: asheet of substrate treated with quillon; and an ink image on said sheet,said ink image made of a composition including a transfer base material,a puff base material, and at least one pigment concentrate.
 7. Thetransfer of claim 6 wherein said substrate is paper.
 8. The transfer ofclaim 6 wherein: said transfer base material is in an amount of at leastabout 25% by weight of said composition; said puff base material is inan amount of at least about 65% by weight of said composition; and saidpigment concentrate is in a total amount of about 10% by weight or lessof said composition.
 9. The transfer of claim 6 wherein: said transferbase material is in an amount of at least about 25% by weight of saidcomposition; said puff base material is in an amount of at least about35% by weight of said composition; and said pigment concentrate is in atotal amount of about 40% by weight or less of said composition.
 10. Thetransfer of claim 6 wherein said puff base material is comprised of aresin, a base, an adhesive, and a blowing agent.
 11. The transfer ofclaim 6 wherein said transfer base material is comprised of a resin anda plasticizer.
 12. A method of making a puff transfer composition, saidmethod comprising: providing a transfer base material, at least onepigment concentrate, and a puff base material; mixing said transfer basematerial, said at least one pigment concentrate, and said puff basematerial together to form a transfer composition.
 13. The method ofclaim 12 wherein said mixing step comprises: mixing said transfer basematerial and said at least one pigment concentrate together to form aninitial composition; and mixing said puff base material and said initialcomposition together to form said transfer composition.
 14. The methodof claim 12 wherein said transfer composition comprises: said transferbase material in an amount of at least about 25% by weight; said puffbase material in an amount of at least about 65% by weight; and saidpigment concentrate in a total amount of about 10% by weight or less.15. The method of claim 12 wherein said transfer composition comprises:said transfer base material in an amount of at least about 25% byweight; said puff base material in an amount of at least about 35% byweight; and said pigment concentrate in a total amount of about 40% byweight or less.
 16. The method of claim 12 wherein said puff basematerial is comprised of a resin, a base, an adhesive, and a blowingagent.
 17. The method of claim 12 wherein said transfer base material iscomprised of a resin and a plasticizer.